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Determination of Elemental Sulfur Deposition Rates For Different Natural Gas Compositions
Determination of Elemental Sulfur Deposition Rates For Different Natural Gas Compositions
Determination of Elemental Sulfur Deposition Rates For Different Natural Gas Compositions
art ic l e i nf o a b s t r a c t
Article history: Natural gas is increasing its share in the worldwide energy market. However, it poses several problems
Received 26 April 2015 during transportation. The formation and deposition of elemental sulfur (S8) in pipelines is the issue that
Received in revised form has the greatest impact on both operational safety and maintenance costs. The formation of S8 as a
28 September 2015
yellow powder may be influenced by changes in operational conditions, such as pressure and tem-
Accepted 8 October 2015
Available online 14 October 2015
perature drops, and by the composition of the natural gas stream. This study aims to examine the
contribution of the nucleation phenomenon to the process of S8 formation and deposition. Simulations
Keywords: were performed using the HYSYSs V7 process simulator, with the Peng-Robinson equation of state, and a
Natural Gas MATLAB routine was devised to calculate the variables affecting the nucleation rate. The influence of
Simulation
natural gas composition on the nucleation rate was evaluated using thermophysical data of average gas
Elemental sulfur
streams from fields of the Brazilian states of Ceará/Rio Grande do Norte (CE/RN), Espírito Santo (ES), Rio
Desublimation
Nucleation de Janeiro (RJ) and Bahia (Fazenda Mamoeiro Field, FSP). The results show that gas composition and
operational conditions may influence the amount of sulfur deposited in the pipelines, and the nucleation
rate increases by reducing the temperature.
& 2015 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.petrol.2015.10.011
0920-4105/& 2015 Elsevier B.V. All rights reserved.
462 J.P.L. Santos et al. / Journal of Petroleum Science and Engineering 135 (2015) 461–465
parameter affecting condensate formation, whereas pressure is the small nuclei grow and disperse, until they reach a certain size
dominant parameter for desublimation. In general, natural gas (critical nucleus) that enables the continuous growth of crystals.
transportation systems operate with high flow rates, low tem- The nucleation process is a microscopic phenomenon that involves
perature drops (due to thermal insulation) and high pressure from tens to thousands of molecules, so it is difficult to observe it
drops (because of turbulent flow). Unless there is a sudden local experimentally in pipelines.
temperature drop in the system, pressure variation seems to be an Zhu et al. (2011) showed that the precipitation of elemental
important parameter to describe the deposition mechanism. Thus, sulfur does not occur immediately at the point in the pipeline
the mechanism of elemental sulfur deposition via nucleation and where the gas stream flows. At this point, the initial concentration
desublimation seems to be more probable. of sulfur in the vapor phase reaches the maximum solubility in
Studies by Pack et al. (2012) validated by actual data on the natural gas. A limit of this barrier, which is controlled by the Gibbs
deposition locations of elemental sulfur in pipelines show that free energy, has to be overcome to form a critical nucleus, based on
flow dynamics in pipelines with “T” junctions may be an im- the Classical Nucleation Theory. The nucleation rate can be ob-
portant parameter affecting preferential deposition in specific lo- tained from the combination of Eq. (1)–(5) according to Turk
cations such as valves. (2000):
The problem has become more evident as natural gas con-
( −ΔG )
sumption has increased, and has created significant operation and J = Ke kBT (1)
maintenance problems, resulting in high costs for the industry.
Thus, the understanding of the problem and the consequent where J is the nucleation rate (cm 3 s 1); K is the pre-exponential
search for a solution are very important for the operation of nat- factor (cm 3 s 1); ΔG is Gibbs free energy (J); kB is the Boltzmann
ural gas transportation systems. Solving the problem can help to constant (J/K); and T is the temperature (K).
reduce maintenance costs and lessen the need for internal The Gibbs free energy is a state function which depends only on
equipment inspections. the initial and final states. Enthalpy and entropy values of the in-
Nucleation has been mentioned as one of the factors that may itial and final states can be obtained from HYSYSs, together with
contribute to sulfur formation and deposition (Pack, 2005; Cézac information on natural gas composition, pressure and tempera-
et al., 2008). However, studies on the nucleation process are still ture. Using these values calculated for the gas streams from the
just beginning, and more research is needed. Therefore, in- desired fields, the variation of the Gibbs energy can be obtained
vestigating the mechanism of elemental sulfur formation is part of from Eq. (2):
the objective of this work, and the aim is to better understand the ΔG = ΔH − T ΔS (2)
contribution of the nucleation phenomenon to the process of S8
formation and deposition. where ΔG is the change in Gibbs free energy (kJ/kg); ΔH is the
change in enthalpy (kJ/kg); ΔS is the change in entropy (kJ/kg K).
The pre-exponential factor of Eq. (1) is given by:
2. Methodology 2σ 1
K = θαcvsN2[ ]2
kBT (3)
The simulations in this work were performed using the HYSYSs
V7 process simulator, using the Peng-Robinson equation of state, where ϴ is the non-isothermal factor (¼1 for diluted mixtures);
and a MATLABs program version R2010a was used to determine αc is the condensation factor (m/s); vs is the solute's molecular
the nucleation rate. The methodology used for the simulations in volume (m³); N is the number of condensable molecules (cm 3);
the HYSYSs was the same used by Pack (2005). Information about and s is the solute's interfacial tension (N/m).
the operational conditions of the Fazenda Mamoeiro Field, which The solute's molecular volume can be calculated for each point
belongs to the Field-School Project (FSP) of the Federal University as a function of temperature, according to Eq. (4):
of Bahia, allowed the simulations to be performed using actual
1
parameters, such as natural gas composition, operating pressure vs = T
and temperature conditions. The influence of natural gas compo-
[M (3 − 2( T ))0.31NA] (4)
b
sition on the homogenous nucleation rate was evaluated using
where M is the molar volume of sulfur (mol/m³); NA is Avogadro's
thermmophysical data of average gas streams produced in the
number (mol 1); and Tb is the bubble point temperature (K).
fields of the Brazilian states of Ceará/Rio Grande do Norte (CE/RN),
The number of condensable molecules is calculated by Eq. (5):
Espírito Santo (ES), Rio de Janeiro (RJ) and Bahia (Fazenda Ma-
moeiro Field, FSP), as shown in Table 1. N = ρM yE NA (5)
Nucleation in natural gas transport is the process by which
where ρM is the density of the mixture (mol/cm³); and yE is the
Table 1 solute's molar fraction under the extraction conditions.
Composition of natural gas samples used in the simulations The interfacial tension of sulfur can be expressed by Eq. (6)
according to Zhu et al. (2011):
Composition (% vol) CE/RN ES RJ FSP
TbrlnPc
Methane 74.53 88.16 79.69 69.79 σ = Pc2/3Tc1/3[0.1207(1 + ) − 0.281](1 − Tr )1.222
1 − Tbr (6)
Ethane 10.40 4.80 9.89 14.33
Propane 5.43 2.75 5.90 6.24
where Pc is the critical pressure (MPa); Tc is the critical tempera-
i-Butane 0 0 0 1.15
Butane 2.81 1.55 2.13 1.83
ture (K); Tbr is the reduced bubble point temperature; and Tr is the
Pentane 1.30 0.44 0.77 1.14 reduced temperature.
C6 þ 1.40 0.44 0.44 0.49 The mass of sulfur that can be deposited through the nuclea-
Nitrogen 1.39 1.62 0.80 3.19 tion/desublimation process at a certain point, based on the rate of
CO2 2.74 0.24 0.50 1.51
nuclei formation, can be obtained using Eq. (7) according to Pack
O2 0 0 0 0.33
H2S (mg/m³) 1.50 7.50 6.70 7.60 (2005):
m = n. MM (7)
Source: Vaz et al. (2008), modified.
J.P.L. Santos et al. / Journal of Petroleum Science and Engineering 135 (2015) 461–465 463
1.40E+09 Gas Processing Unit (NGPU) with pressure and temperature simi-
lar to those of the plant that receives the gas produced at the
1.20E+09 Hasbah field, that is, 800psia (5414.4 kPa) and 35 °F (275 K).
The nucleation rate obtained by running the MATLABs routine
1.00E+09
for the conditions downstream of the restriction was
1.03 1013 cm 3 s 1. This value is in accordance with Pack (2005),
J (cm-3s-1)
8.00E+08
within an order of magnitude of the 1013 cm 3 s 1 value given by
the author for restrictions. The sulfur mass that would be de-
6.00E+08
posited for this nucleation rate was calculated using the afore-
4.00E+08
mentioned procedure. It is noteworthy that the amount of sulfur
that could desublimate at this point was considered equal to
2.00E+08 0.0099 ppm, as reported by Alami et al. (2012). The nucleation rate
translates to 4.77 1023 nuclei per day. The sulfur mass deposited
0.00E+00 downstream of the valve, determined by Eq. (7), is as follows:
300 310 320 330 340 350
Temperature (K) m = (4.77 × 1023/6.023 × 1023) × 32.06 = 9.7 kg/year
Fig. 2. Nucleation rate profile as a function of temperature along the pipeline in the This value is on the same order of magnitude as that of Pack
Fazenda Mamoeiro Field (FSP). (2005), who estimated 1.075 kg/year of sulfur deposited down-
stream of a certain point for a gas stream with 0.009 ppm of sulfur.
low nucleation rate along the studied line. However, very low It has to be mentioned that the author found a lower mass for a
temperatures may occur in pressure-reduced conditions, for ex- similar sulfur concentration (0.009 ppm) because pressure and
ample in restrictions, and nucleation rates may reach much higher temperature conditions were different. The author considered a
values in those cases. This can be observed in the behavior of the temperature of 288.65 K at the reduction stage, whereas this study
curve in Fig. 2, which increases exponentially to very high nu- uses a value of 275 K.
cleation rates at very low temperatures, as in the case of pressure The values obtained for the line and the restriction confirm
reductions. According to Pack (2005), nucleation rates may reach previous results showing that a higher amount of deposited sulfur
values on the order of 1013 cm 3 s 1 in restrictions, which ex- is found downstream of the restriction points. More particle–
plains why these places have larger amounts of elemental sulfur particle collisions occur at these locations, enabling a higher de-
deposited downstream of valves. gree of agglutination and larger particle sizes. This is enhanced by
The mass of sulfur deposited along the pipeline can be esti- the effect of a pressure and temperature drop that makes the
mated from the nucleation rate profile. Thus, the calculated values stream supersaturated with sulfur. Differences in nucleation at
for the 100 points along the pipeline were used to estimate the different pressure and temperature conditions make it easier to
average nucleation rate. The average nucleation rate was understand why some points show visible deposition of elemental
6.26 108 cm 3 s 1 for a 35-meter section of pipeline. Using the sulfur and others do not.
average nucleation rate, the line's operational conditions, the gas The nucleation rates in the pipeline and the restrictions enable
production flow rate of the Fazenda Mamoeiro field and the gas to assess the effect of pressure and temperature on the deposition
composition given in Table 1, the rate is 1.49 1022 nuclei/day. phenomenon. However, as previously discussed, the composition
Using the molecular mass of sulfur (32.06 kg/kmol) in Eq. (7), the of the gas stream is another parameter that may influence sulfur
mass of sulfur deposited in the pipeline is deposition in pipelines. Thus, the same operational conditions of
pressure, temperature, production flow rate and amount of sulfur
m = (1.49x1022 /6.023x1023) × 32.06 = 0.291 kg/year in the FSP gas stream were used to calculate the nucleation rate
The amount of sulfur deposited in the pipeline is small com- profiles of the gas streams of the CE/RN, ES and RJ fields, whose
pared to the values that can be deposited downstream of the re- compositions are shown in Table 1. The only variable that has to be
strictions. However, the small amount of deposited sulfur can be modified in the routine for each field is the change in Gibbs free
explained by two factors. First, the very short extension of the line energy; the other variables are calculated as functions of tem-
(35 m) resulted in a small pressure drop, which reduces the pos- perature. The comparative results showing the influence of natural
sibility of sulfur supersaturation in the gas stream. Second, the gas composition on the nucleation rate profile are shown in Fig. 3.
nucleation rate was calculated for a pipe segment with no re- Fig. 3 shows that the composition of the gas stream influences
strictions; therefore, gas was able to flow in a wider space with the homogenous nucleation rate profile, even though the different
less turbulent conditions. The number of molecules that collide streams have the same operational conditions. Nucleation rates
inside the pipeline is low under such conditions, and the particles are very similar for all compositions at high temperatures, when
formed are very small and can be transported together with the sulfur concentration is close to the maximum solubility in the gas
gas stream for longer distances, with little deposition in the pi- stream. However, the curves are separated when the temperature
peline. The objective of this calculation was to demonstrate that is reduced because of the cooling effect of the pipeline. Thus, the
the amount of sulfur deposited in unrestricted pipeline sections is influence of the gas composition becomes more significant at very
actually very small, and does not cause a significant loss of flow low temperatures, as can occur in restrictions. A comparison of the
area. However, even small amounts of sulfur deposited along the curves for gas streams from the ES and CE/RN fields, which have
pipeline may cause corrosion problems and affect transportation very different compositions, shows that, at low temperatures, the
operational safety. nucleation rates of the gas from the ES field grow exponentially
As previously discussed, the more serious problems of ele- and reach much higher values than those of the gas stream from
mental sulfur deposition occur downstream of restrictions in pi- the CE/RN field.
pelines. In these places, the gas stream may reach very low pres- The differences between the curves can be explained by the
sures and temperatures because of the Joule-Thompson effect. To tendency of the gas stream to form droplets at low temperatures.
evaluate the effect on nucleation rate at these locations, a situation When the gas stream has a higher fraction of heavy components
was considered in which the FSP gas was delivered to a Natural (C3 þ), as in the case of the CE/RN field, the probability of forming
J.P.L. Santos et al. / Journal of Petroleum Science and Engineering 135 (2015) 461–465 465
8.00E+08 Acknowledgments
6.00E+08
The authors thank the Bahia Research Foundation (Fundação de
4.00E+08 Amparo à Pesquisa do Estado da Bahia - FAPESB) for financing the
Project, grant number APP 0008/2011, and the Graduate Studies
2.00E+08
Program in Chemical Engineering (Programa de Pós-Graduação em
0.00E+00 Engenharia Química) of the Federal University of Bahia (Uni-
300 310 320 330 340 350
versidade Federal da Bahia - UFBA).
Temperature (K)
Fig. 3. Influence of gas stream composition on the nucleation rate profile.
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